DIY Network

Vespa Finale: Route Control Cable and Assemble Brakes From "Classic Rides" episode DCLR-113

Figure A

In the first segment host Kevin Tetz and Greg West, a Vespa restoration expert, mounted the turn signals and installed the headset. In this segment the control cables will be routed and the brakes will be assembled.

Greg says one of the first things he likes to do when the housings are in place is to go ahead and drop the cables in them, which will prevent the housings from slipping back down to where you'd have to fish them out.

Routing the Control Cables

• Feed the gear selector cable (figure A) through the housing and into the seat well, and rotate the selector forward and hook up the selector cable using needle-nose pliers.

• Repeat the same process with the other gear selector cable.

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	Figure B
	Figure C
	Figure D
	Figure E
	Figure F

• Next is the throttle control cable. Greg has to use hemostats to get back in to where he can get a hold of the cable. Install the throttle cable into the guide with the hemostats (figure B).

• The clutch cable comes next. The thing about the clutch cable and housing is that they have to go through a torturous path to get where they're connected. Greg says it's best to run the cable through first, and then slide it into the housing. Then you can slide the housing up on the cable to guide it through the maze.

• Run the cable through the headset assembly, and slide the cable into the housing.

• Slip the cable into the clutch lever (figure C) and take out the slack from the cable. This helps pull the lever into place.

• To set the tension on the clutch lever, install the screw and tighten it down enough so there's some free play in the lever.

• Install the nut locking the tension in place.

• Fish the brake cable through the headset, and feed it down through the housing assembly. Push the housing back up the cable so you can install the lever.

• Attach the hardware to secure the lever and make sure the tension on the lever has a little give (figure D).

  Note: There's a cam mechanism (figure E), which is the lever that actuates the brake, and you'll be running the cable right through catching it with the pinch bolt.

• Tighten down the cable tensioning tool (figure F) so it won't slip back out.

• Feed the rear brake cables through the scooter body and into the seat well.

• Slide the housing over the cable, and hook up the pin for the brake pedal.

• Put tension on the brake pedal and tighten it up.

Note: Follow the manufacturer's schematic instructions for hooking up the headlight.

In the next segment Kevin and Great install a 12-volt ignition kit to the Vespa.

RESOURCES :

Eazyrizer Big Blue Motorcycle Lift (Driven Gear)
Driven Gear Inc.
Website: www.drivengear.com

RaceDeck Modular Flooring (SnapLock Industries)
SnapLock Industries
Website: www.racedeck.com

Vespa Restoration Parts (Scomo)
Scomo
Website: www.scomo.net

Air Compressor (Bend-Pak)
Bend-Pak, Inc.
Website: www.bendpak.com

Stock Photos, Videos, CD Rom and Timesurfer (Piaggio)
Piaggio, USA, Inc.
Website: www.piaggio.com/

GUESTS :

Greg West
Scooter Restoration Expert
E-mail: wheelsX2@yahoo.com